Production of phenol-methylene resins and alcohol from methylals



Patented Oct. 11, 1927.

UNITED] STATES PATENT OFFICE.

CARRIE B. CARTER, OI PITTSBURGH, PENNSYLVANIA, ASSIGNOR TO S. KARPEN & BROS, OF CHICAGO, ILLINOIS, A CORPORATION OF WEST VIRGINIA.

PBODUGTION OF PHENOL-METEYLENE RESINS AND ALCOHOL FROM IlETHYLALS.

No Drawing.

The present invention is in the nature of a process for producing phenolic condensation products and alcohol from phenols and methylals. The primary object is to provide-a simple and practical method of producing phenolic condensation products from the materials nfentioned quickly, operating at atmospheric pressures. A further object is to produce alcohol by a reaction carried on in the manner indicated.

The methylals are dirivatives of formaldehyde and alcohols. They are formed conveniently by the condensation of an alcohol is with formaldehyde, in the presence of an acid condensing agent. The condensation may be represented by the reaction between formaldehyde and methyl alcohol to produce dimethyl methylal: 2CH OH+ CH,O 011 0011 0611, H O

It is only necessary in order to eifect the condensation to mix 1.5 parts of methyl alcohol, containing 1% to 2 hydrochloric and 1 part of fused calcium chloride and allow the mixture to stand at ordinary temperatures for several hours. Methylal is then recovered from the resulting mixture by fractional distillation. Yields amounting to 75% to 80% of the theoretical value may be obtained in this way.

A large number of methylals may be 'pre-' pared from formaldehyde and the various alcohols. the methyl alcohol used in the preparation above is substituted by ethyl, propyl, butyl etc., alcohols we obtain the following serles of methylalsx Boili(n %p)oint Dimethyl methylal C11 0) 0H, 42 Diethyl methylal H O) 0H, 89 Dipropyl methylal (C H,O) CH 137 Dibutyl methylal (O4H9O)2CH2 164 The meth la'ls are liquids which are quite stable in t e presence of alkalies, but which are more or less easily hydrolyzed in the presence of acids to ,formaldehyde and the corresponding alcohols.

The methylals condense with phenol or 55 ether, acetone, etc, if the phenol and the acid, with 1 part of commercial formalin cresols' in the presence of water and an acid Application fllcd August 26, 1925. Serial No. 52,685.

methylal are condensed in the proper proportions to produce resins of this character. Acids which may be employed advantageously in the present process are the mineral acids, such as sulphuric, hydrochloric and phosphoric acids. Of these, sulphuric acid is preferred, particularly where the condensation product is to be employed in a molding com ound. In such case, after washing the fusible, soluble resin, any remainin traces of acid may be readily neutralize by use of lime, for example.

In accordance with the present invention, the acid is employed in rather high proportion, preferably constituting about 20% of the reacting'mixture, and the condensation is effected at atmospheric pressure.

An example of a suitable reacting mixture for the process is as follows:

Grams. 7'5 Methylal ..c 4. 6 Phenol 8." 5 Water 22. 8 Sulphuric acid 9. 1

Such a solution contains 20% acid, and the phenol and methylene groups are present in the proportion of ninephenolic groups to six methylene groups. By boiling this solution under a reflux condenser at at- 35 'I'nospheric pressure, reaction ,will be completed in the course of a few inutes. The reaction products will'comprise a fusible, soluble phenolic resin, methylalcohol equivalent to the two mole of alcohol required to form methylal from formaldehyde, and also water and the acid. The reaction is exothermic in character; and when large batches are employed, the heat involved by the reacton, after the mixture has been brought to "boiling is sufiicient to cause the reaction to continue. The application of heat may be continued, however, as long as it may be found desirable.

In practice, a phenol and a methylal by using a sultable vessel of acid-resisting material, such as glass, or metal enameled; so as to be acidproof, equipped with a suitable form of condenser. phenol, methylal, and preferably w1th about an equal quantity of aqueous ac1d, contaming 20% more or less of acid. The charge is heated at the boiling point for a suflicient time to cause the reactionto complete itself; 110

resins may be produced from Such a vessel is charged with the the reflux condenser then is cut out of the system, or by-passed, and the reaction products are subjected to distillation to remove alcohol and a part of the water. The aqueous alcoholic condensate recovered in the distillation is subjected to a second distillation in order to separate the alcohol from the water and to effect its recovery. The resin in the still is tapped off from the aqueous acid layer and is washed several times by a itation with hot water, or by kneading wlth cold water. The wash water from the first few washings is added to the recoveredacid in order to conserve acid, and also to conserve such amounts of free phenol as may be present in the solution. The re covered acid is used again and again in the operation of the process.

' to each me The resin, after thorough washing to remove acid, ma be heated to elevatedtemperatures to e ect drying, and also, if desired, to remove some of the excess phenol. It then is in form for use, it being only necessary to add the required quantities of hardening agents, fillers, solvents, etc., in

order to transform it into the infusible, in-,

soluble resinous products known in the arts.

Any suitable 'henolic body may be employed in lieu o phenol. For examfple, the

cresols may be condensed with equal acility; and -the dimethyl methylal may be suplanted b the various methylals derived rom ethy ,propyl, butyl, etc.,.alcohols. The

' reaction 1s general for the methylals as a class of substances.

The methylals are quite stable in the presence of aqueous alkalies, so that alkalies or bases are not suitable to be used for condensing agents.

Usually it is desirable to employa considerable excess of the phenolic body, say enough to give about 1 phenolic groups tylene group. This produces a fusible and soluble resin, and, after some of the excess phenol, say 10% or more, is blown off, the resin still remains fusible and soluble, but at room temperature is hard and brittle.

The fusible and soluble resin may be employed in producing a final infusible and substantially insoluble phenolic condensation product in accordance with known methods.

For example, hexamethylenetetramine, 'formaldehyde, or other suitable active methylene body, may be mixed with the fusible and soluble resin in sufficient ro ortion to give to the mass about one met y ene group to each phenolic group. When such mass is subjected to the action of heat, for a suitable length of time the mass is converted to the final infusible and substantially insoluble state.

Before conversion to the final state, suitable dyes or pigments and suitable filling materials may desired.

be mixed with the mass, if

It may be stated that the reaction mixture may comprise additional materials. For example, instead of employing pure methylal in the process, one may employ a byproduct solution obtained in the manufacture of As an example of themanner in which such a solution may be employed in the process by mixing with the solution suitable percentages of phenol and acid, the'following is given as an instance of suitablereactmg mixture:

Grams. Methylal s 4. 5 Phenol 10.7 Methyl alcohol 1.7 Formaldehyde 0.4 Water 15.6 Sulphuric aci'd 11.1

plete in the course of a few minutes, but

heating was continued for two hours in order to ensure complete reaction. After two hours, 25 cc. of water was added to the flask, and the reaction liquor showing the resinous layer at the bottom of the flask, was subjected to distillation in order to remove the alcohol. The resin, almostdevoid of color, could be kneaded in ice water, or agitated with hot water to effect washing. .The resin, freed from acid, was heated one hour at 150 C. to 160. C. It was quite fluid at the elevated temperature, but set on cooling to room temperature to a transparent, slightly greenish solid, possessing the properties of a ninesix resin prepared from phenol and hexamethylenetelramine. That is, such a resin contains about 1 A phenol groups to each methylene group.

It has been demonstrated by'numerous experiments that the proportions of the materials present in the reacting mixture may be varied within rather wide limits. It is desirable,-however, to use a sufiiciently large proportion of the phenolic body employed to permissible in view of the prior art.

body, a solution of active methylene body ensures the production of a good product and obviates danger of failure. The fusible, soluble product can be readily washed, or purified; and any remaining traces of acid may be neutralized. This is easily eifected, in the case of the use of sulphuric acid, by introducing a little lime. Again, the amount of aqueous acid present in the reacting mixture may vary greatly, so long as a suitable strength is preserved. In the case of sulphuric acid, it is preferred to have the acid present to the extent of about 20% of the reacting .mixture. A practicable range for sulphuric acid is from about 10% to about 30% of the reacting mixture.

Hydrochloric acid will effect very rapid reaction, but its use is not so desirable where the resin is. to be employed in a molding compound. Phosphoric acid may be used as an equivalent, but a higher percentage is necessary in order to obtain the same expedition in carrying on the reaction. Organic acids are not sufiiciently powerful to indicate the desirability of their use as a catalyst in the present process.

The foregoing detailed description has ,been' given for clearness of understanding only, and no unnecessary limitations should be understood therefrom, but the appended claims should be construed as broadly as v.What I regard as new, and desire to secure by Letters Patent, is: i

1. The method of producing a phenolic condensation product which comprises boiling at substantially atmospheric pressure a phenolic body, a solution of methylene body consisting principally of methylal and mineral acid, the mineral acid being present in excess of ten per cent of the reacting mixture; and recovering and puriqing the phenolic condensation product pro uced by the reaction.

2. The method ofproducing a phenolic condensation product which comprises boiling under a reflux condenser a phenolic consisting principally of methylal and a mineral acid, the phenolic body being taken in substantial excess of an'equi-molecular proportion and the acid constituting at least ten er cent of the reacting mixture; continuing the operation untilthe reaction is substantially completed; boiling off and recovering the alcohol produced; and recovering and purifying the phenolic condensation j pro duct produce 3. The process of producing a phenolic condensation product which comprises boiling under a reflux condenser a mixture comprising methylal, a phenolic body taken in substantial excess of an equi-molecular proportion so as to produce .a fusible, soluble resin, and mineral acid in roportion constituting at least substantial y ten per cent of the reacting mixture, such operation being continued until the reaction is substantially completed; and separating the phenolic condensation product from the reacting mixture.

4. The process of producing a phenolic condensation product which comprises: boiling under a reflux condenser a mixture comprising a phenolic body and'methylal in the presence of water and mineral acid, the

phenolic body being in such substantial ex cess of an equi-molecular proportion as to produce'a fusible, soluble resin and the acid constituting at least substantially ten per cent of the reacting mixture, such ope-ration being continued until the reaction is substantially complete; boiling off and recovering the alcohol; and separating and purifying the resin formed.

5. The process of producing a phenolic condensation product which comprises: boiling under a reflux condenser a phenolic body and an active methylene bo y consisting principally of methylal in the presence of water anda mineral acid constituting about twenty per centof the reacting mixture, such ope-ration being continued until the reaction is substantially complete; distilling water and aclohol from the reacting mixture and recovering the alcohol; separating the resin from the remaining liquid and washing it; and adding to the purified resin asuflicient quantity of an active methylene body to enable conversion to a final and fusible state to be effected.

6. The method of producing a phenolic condensation product which comprises boiling at substantially atmospheric pressure a mixture comprising the following materials in about the proportions stated, viz.:

7. The method described in claim 6 characterized by the recovery and purifying of. the condensation product produced by the reaction.

OARN IE B. CARTER. 

